NISSAN PICK-UP 2001 Repair Manual

COMPONENT DESCRIPTION
EGR volume control valve
The EGR volume control valve uses a step motor to control the
flow rate of EGR from exhaust manifold. This motor has four
winding phases. It operates according to the output pulse signal
of the ECM. Two windings are turned ON and OFF in sequence.
Each time an ON pulse is issued, the valve opens or closes,
changing the flow rate. When no change in the flow rate is
needed, the ECM does not issue the pulse signal. A certain
voltage signal is issued so that the valve remains at that particu-
lar opening.
CONSULT-II Reference Value in Data Monitor
Mode
Specification data are reference values.
MONITOR ITEM CONDITION SPECIFICATION
EGR VOL CON/V+Engine: After warming up
+Air conditioner switch: ªOFFº
+Shift lever: Neutral position
+No-loadAfter 1 minute at idle More than 10 steps
Revving engine up to 3,200 rpm
quickly0 step
ECM Terminals and Reference Value
Specification data are reference values and are measured between each terminal and ground.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may damage the
ECM's transistor. Use a ground other than ECM terminals, such as the ground.
TER-
MINAL
NO.WIRE
COLORITEM CONDITION DATA (DC Voltage)
103
105
109
115GY
OR/B
W/L
SBEGR volume control valveEngine is running.
Warm-up condition
Idle speed0.1 - 14V
DTC Confirmation Procedure
WITH CONSULT-II
1) Start engine and warm it up to normal operating temperature.
2) Select ªDATA MONITORº mode with CONSULT-II.
3) Turn ignition switch ªOFFº, and immediately turn ªONº within
1 second.
4) Start engine and let it idle.
5) If DTC is detected, go to ªDiagnostic Procedureº, EC-3610.
WITHOUT CONSULT-II
1) Start engine and warm it up to normal operating temperature.
2) Turn ignition switch ªOFFº, and immediately turn ªONº within
1 second.
3) Start engine and let it idle.
4) Turn ignition switch ªOFFº, wait at least 5 seconds and then
turn ªONº.
5) Perform ªDiagnostic Test Mode II (Self-diagnostic results)º
with ECM.
6) If DTC is detected, go to ªDiagnostic Procedureº, EC-3610.
SEF411Y
SEF817Y
DTC 1003 EGR VOLUME CONT/VYD25DDTi
Description (Cont'd)
EC-3606

Wiring Diagram
LHD MODELS
GEC284A
DTC 1003 EGR VOLUME CONT/VYD25DDTi
EC-3607

RHD MODELS
GEC285A
DTC 1003 EGR VOLUME CONT/VYD25DDTi
Wiring Diagram (Cont'd)
EC-3608

Diagnostic Procedure
1 CHECK EGR VOLUME CONTROL VALVE POWER SUPPLY CIRCUIT-I
1. Turn ignition switch ªOFFº.
2. Disconnect EGR volume control valve harness connector.
SEC231D
3. Turn ignition switch ªONº.
4. Check voltage between EGR volume control valve terminals 2, 5 and ground with CONSULT-II or tester.
SEF412Y
OK or NG
OKcGO TO 7.
NGcGO TO 2.
DTC 1003 EGR VOLUME CONT/VYD25DDTi
EC-3609

2 CHECK EGR VOLUME CONTROL VALVE POWER SUPPLY CIRCUIT-II
1. Turn ignition switch ªOFFº.
2. Disconnect ECM relay.
SEC950C
3. Check harness continuity between ECM relay terminal 3 and EGR volume control valve terminals 2 and 5. Refer to Wiring Dia-
gram.
Continuity should exist.
OK or NG
OKcGO TO 4.
NGcGO TO 3.
3 DETECT MALFUNCTIONING PART
Check the following.
+Harness connectors E101, M5
+Harness connectors M278, E236 (LHD models)
+Harness connectors M47, F55 (RHD models)
+Harness connectors F35, E236 (RHD models)
+Harness for open or short between EGR volume control valve and ECM relay
cRepair open circuit or short to ground or short to power in harness or connectors.
4 CHECK EGR VOLUME CONTROL VALVE POWER SUPPLY CIRCUIT-III
Check voltage between ECM relay terminal 5 and ground with CONSULT-II or tester.
SEC167D
OK or NG
OKcGO TO 6.
NGcGO TO 5.
DTC 1003 EGR VOLUME CONT/VYD25DDTi
Diagnostic Procedure (Cont'd)
EC-3610

5 DETECT MALFUNCTIONING PART
Check the following.
+10A fuse
+Harness for open or short between ECM relay and battery
cRepair open circuit or short to ground or short to power in harness or connectors.
6 CHECK ECM RELAY
1. Apply 12V direct current between ECM relay terminals 1 and 2.
2. Check continuity between ECM relay terminals 3 and 5, 6 and 7.
SEF296X
OK or NG
OKcGO TO 7.
NGcReplace ECM relay.
7 CHECK EGR VOLUME CONTROL VALVE OUTPUT SIGNAL CIRCUIT FOR OPEN AND SHORT
1. Turn ignition switch ªOFFº.
2. Disconnect ECM harness connector.
3. Check harness continuity between ECM terminals and EGR volume control valve terminals as follows.
Refer to Wiring Diagram.
MTBL0442
Continuity should exist.
4. Also check harness for short to ground and short to power.
OK or NG
OKcGO TO 9.
NGcGO TO 8.
8 DETECT MALFUNCTIONING PART
Check the following.
+Harness connectors E236, M278 (LHD models)
+Harness connectors E236, F35 (RHD models)
+Harness for open or short between ECM and EGR volume control valve
cRepair open circuit or short to ground or short to power in harness or connectors.
DTC 1003 EGR VOLUME CONT/VYD25DDTi
Diagnostic Procedure (Cont'd)
EC-3611

9 CHECK EGR VOLUME CONTROL VALVE-I
Check resistance between EGR volume control valve terminal 2 and terminals 1, 3, terminal 5 and terminals 4, 6.
SEF414Y
OK or NG
OK (With CONSULT-II)cGO TO 10.
OK (Without CONSULT-II)cGO TO 11.
NGcReplace EGR volume control valve.
10 CHECK EGR VOLUME CONTROL VALVE-II
With CONSULT-II
1. Remove EGR volume control valve.
2. Reconnect ECM harness connector and EGR volume control valve harness connector.
3. Turn ignition switch ªONº.
4. Perform ªEGR VOL CONT/Vº in ªACTIVE TESTº mode with CONSULT-II.
5. Check that EGR volume control valve shaft moves smoothly forward and backward according to the valve opening steps.
SEF819Y
OK or NG
OKcGO TO 12.
NGcReplace EGR volume control valve.
DTC 1003 EGR VOLUME CONT/VYD25DDTi
Diagnostic Procedure (Cont'd)
EC-3612

11 CHECK EGR VOLUME CONTROL VALVE-II
Without CONSULT-II
1. Remove EGR volume control valve.
2. Reconnect ECM harness connector and EGR volume control valve harness connector.
3. Turn ignition switch ªONº and ªOFFº.
4. Check that EGR volume control valve shaft moves smoothly forward and backward according to the ignition switch position.
SEF560W
OK or NG
OKcGO TO 12.
NGcReplace EGR volume control valve.
12 CHECK INTERMITTENT INCIDENT
Refer to ªTROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENTº, EC-3469.
cINSPECTION END
DTC 1003 EGR VOLUME CONT/VYD25DDTi
Diagnostic Procedure (Cont'd)
EC-3613

Description
SYSTEM DESCRIPTION
The ECM and the electronic control fuel injection pump control
unit (abbreviated as the injection pump control unit) perform the
real time communication (signal exchange).
The ECM transmits the signals of the target fuel injection
amount, target fuel injection timing, and engine speed, etc., and
receives the signals of the pump speed and fuel temperature,
etc. from the injection pump control unit.
By those signals, the injection pump controls the optimum fuel
injection amount and injection timing of the spill valve and tim-
ing control valve.
Injection pump control unit has an on board diagnostic system,
which detects malfunctions related to sensors or actuators built-
into electronic control fuel injection pump. These malfunction
information are transferred through the line (circuit) from injection
pump control unit to ECM.
FUEL INJECTION AMOUNT CONTROL
In accordance with the target fuel injection amount signal from
the ECM, the injection amount is controlled by controlling the spill
valve in the injection pump and by changing the needle opening
time.
FUEL INJECTION TIMING CONTROL
Based on the target fuel injection timing signal from the ECM, the
injection timing is controlled in accordance with the timer spring
by performing the duty control of the timing control valve in the
injection pump and by adjusting the pressure of the timer piston
high pressure chamber.
FUEL TEMPERATURE SENSOR
The sensor detects the fuel temperature in the injection pump
and calibrates the injection amount change by the fuel tempera-
ture.
CAM RING POSITION SENSOR
The sensor detects the passing of the protrusion on the sensor
wheel in the injection pump by the semiconductor magnetic
resistance element sensor. The cam ring position sensor syn-
chronizes with the cam ring, and detects the actual advance
amount. The injection pump control unit measures the injection
pump revolution by the signal of the cam ring position sensor.
SEF437Y
DTC 1004 FUEL CUT SYSTEM1YD25DDTi
EC-3614

CONSULT-II Reference Value in Data Monitor
Mode
Remarks: Specification data are reference values.
MONITOR ITEM CONDITION SPECIFICATION
FUEL TEMP SEN+Engine: After warming up More than 40ÉC (104ÉF)
SPILL/V+Engine: After warm-
ing upIdle Approx. 13ÉCA
INJ TIMG C/V+Engine: After warming up,
idle the engine.Approx. 50 - 70%
DECELER F/CUT+Engine: After warm-
ing upIdle OFF
BARO SEN+Ignition switch: ONAltitude
Approx.0m(0ft): Approx. 100.62 kPa (1.0062 bar, 1.026 kg/cm
2, 14.59
psi)
Approx. 1,000 m (3,281 ft): Approx. 88.95 kPa (0.8895 bar, 0.907 kg/cm
2,
12.90 psi)
Approx. 1,500 m (4,992 ft): Approx. 83.16 kPa (0.8316 bar, 0.848 kg/cm
2,
12.06 psi)
Approx. 2,000 m (6,562 ft): Approx. 78.36 kPa (0.7836 bar, 0.799 kg/cm
2,
11.36 psi)
ECM Terminals and Reference Value
Specification data are reference values and are measured between each terminal and ground.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may damage the
ECM's transistor. Use a ground other than ECM terminals, such as the ground.
TER-
MINAL
NO.WIRE
COLORITEM CONDITION DATA (DC Voltage)
33 G/YElectronic control fuel
injection pumpEngine is running.
Warm-up condition
Idle speedApproximately 2.4V
40 PUElectronic control fuel
injection pumpEngine is running.
Warm-up condition
Idle speedApproximately 2.4V
52 L/WElectronic control fuel
injection pumpEngine is running.
Idle speedApproximately 0.1V
53 L/RElectronic control fuel
injection pumpEngine is running.
Idle speedApproximately 0.45V
Engine is running.
Engine speed is 2,000 rpmApproximately 0.7V
On Board Diagnosis Logic
Malfunction is detected when .... Check Items (Possible cause)
+Fuel cut control system does not function properly.+Harness or connectors
(Electronic control fuel circuit is open or shorted.)
+Electronic control fuel
DTC 1004 FUEL CUT SYSTEM1YD25DDTi
EC-3615